Automated NDT - Demonstration of robotised inspection for NLA & thermography inspection of internal and external cracks for AM parts
Project challenges
Additive Manufacturing (AM) provides a great amount of freedom to design and build very complex parts, unfortunately, the more complex the part geometry externally and internally the more difficult it is to inspect.
Business challenge
Process Innovation
Sector
Aerospace
Technology or capability
Metrology & NDT
Manufacturing Systems
Automation & Robotics
Project Challenges
With IUK funding the MTC and partners have completed the demonstration of an automated NDT inspection of AM parts using this hybrid NDT approach.
Additive Manufacturing (AM) provides a great amount of freedom to design and build very complex parts, unfortunately, the more complex the part geometry externally and internally the more difficult it is to inspect.
Due to this part complexity, the general inspection practice has relied mainly on X-ray Computed Tomography (XCT) which is a very expensive and time-consuming non-destructive testing (NDT) method.
MTC's Solution
The MTC, with the help of the RASCAL partners, has developed and integrated a robotic sub-system to inspect post process AM parts using thermography and Non-Linear Acoustic (NLA) NDT methods.
This hybrid approach has the potential for faster inspection time and less expensive equipment. Also, due to this hybrid approach, it can cover both macro and micro scale defects.
Industrial visitors attending the demo were very impressed by the system, the feedback given highlighted the potential use of the system in an industrial production line.
Wilson Vesga, Advanced Research Engineer - Non-Destructive Testing
The Outcome
The MTC’s robotise NDT system for NLA and thermography was able to detect small cracks in AM post process build parts.
The system was able to detect small cracks with a dimension of 25 µm in the ACE cups and hinge bracket. With the aid of the software designed and developed by Jefsoft to handle both inspection techniques, it was possible to gather the results from the inspections and displayed the potential for automated sentencing.
Benefits to the Client
The robotic cell demonstrator allows the automatic inspection of the integrity of AM parts using non-linear acoustics resonance and thermography inspection techniques, enabling the ability to discard the build AM parts that are out of tolerance or containing crack defects and delamination both at the surface and internally.
The novel hybrid development in an automated NDT inspection system can produce pass or fail automatically and automatically demonstrate defect recognition. Notches of up to 100 µm were detected in the build part using the thermography system.
The system has also shown the ability to perform inspection and make decisions with limited human input, and can be implemented as a new inspection method for AM right after the build before any post processing such as machining.
